Torque Box Front Side Member Joint for Battery Floor Crash Loads
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Solution Overview
Problem
In vehicles with batteries under a floor panel, the existing connection methods between front side members and cross members are insufficient to absorb collision energy effectively, leading to potential separation and damage during head-on collisions, and also restrict the space available for batteries due to the need for additional connecting members.
Innovation Solution
A configuration where the proximal end of the front side member is directly and firmly joined to the inner surface of a torque box, eliminating the need for extension side members, allowing for increased battery space and enhanced collision energy absorption through deformation of the front side member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extension side members are used to connect front side members to cross members, then connection strength is improved, but battery space is reduced
Solution Approach 1:
The front side member is merged with the torque box structure by directly joining the proximal end portion of the front side member to the inner surface of the torque box. This integration eliminates the need for separate extension side members while maintaining connection strength, thereby increasing battery space.
Solution Approach 2:
The proximal end portion of the front side member is positioned within the internal space of the torque box and joined to its inner surface. This nesting arrangement allows the front side member to be accommodated within the existing torque box structure without requiring additional external connecting members.
2Reliability
If extension side members are used to connect front side members to cross members, then connection reliability is improved, but device complexity is increased
Solution Approach 1:
The front side member and torque box are merged into an integrated structure where the proximal end portion of the front side member is directly joined to the torque box inner surface. This reduces the number of separate components and connections required, simplifying the overall structure while maintaining reliability.
Solution Approach 2:
The extension side members are extracted/removed from the structure. By eliminating these intermediate connecting members and directly joining the front side member to the torque box, the structure is simplified without compromising connection reliability.
3Volume of moving object
If front side members are directly connected to cross members without extension side members, then battery space is increased, but connection strength is reduced
Solution Approach 1:
The front side member is merged with the torque box by direct joining of the proximal end portion to the inner surface, creating a unified structural element that eliminates the need for extension side members while maintaining adequate connection strength.
Solution Approach 2:
The proximal end portion of the front side member is designed with a curved surface that conforms to the inner surface of the torque box. This curved geometry increases the contact area and improves the joining strength, enabling direct connection without extension members.
4Device complexity
If front side members are directly connected to cross members without extension side members, then device complexity is reduced, but connection reliability is reduced
Solution Approach 1:
The front side member and torque box are merged into an integrated structure, reducing component count and complexity while maintaining reliable connection through direct joining of the proximal end portion to the torque box inner surface.
Solution Approach 2:
The curved surface design of the proximal end portion increases the contact area with the torque box inner surface, improving joining reliability. The curved geometry distributes stresses more effectively, enhancing connection reliability without requiring additional members.
Data Source
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AI summary
A vehicle (100) includes a floor panel (7), a battery (10), a rocker (8L, 8R), a torque box (6L, 6R), and a front side member (4L, 4R). The torque box (6L, 6R) extends inward in the vehicle width direction from a front end of the rocker (8L, 8R) along a front edge (7F) of the floor panel (7). The torque box (6L, 6R) includes a front wall (61R, 62R) and a rear wall (64R) that face each other in the vehicle length direction. The front wall (61R, 62R) and the rear wall (64R) define an internal space (S 1) extending in the vehicle width direction. The front side member (4L, 4R) extends forward in the vehicle length direction from the torque box (6L, 6R), and includes a proximal end portion (40L, 40R) at a rear end of the front side member (4L, 4R). The proximal end portion (40L, 40R) is located in the internal space (S 1) of the torque box (6L, 6R), and is joined to an inner surface of the torque box (6L, 6R) in the internal space (S1).